Apparatus for preparing inner trim panels



April 30, 1940. c. w. AVERY APPARATUS FOR PREPARING INNER TRIM'PANELS Fiied Dec. 12, 1935 3 Sheets-Sheet 1 INVENTOR.

Clarence M fl/erg BY 0'" irrofi lv y s.

April 1940- A c. w. AVERY 2,199,062

APPARATUS FOR PREPARING INNER TRIM PANELS Filed Dec. 12, 1935 3 Sheets-Sheet 2 5P. INVENTOR.

/ Clan-vice llflrer ATTORNEYS.

April 30, 1940. c.. w. AVE RY 2,199,062

APPARATUS FOR PREPARING INNER TRIM PANELS I Filed Dec. 12, 1935 3 Sheets-Sheet 3 4 I INVENTOR.

A TTORNEYS.

Patented Apr. 39. 1940 UNITED S ATES reener-us roa eas'PARINo imisa TRIM PANELS Clarence W. Avery, Detroit, Mich, assignor to The Murray Corporation of America, a corporation of Delaware Application December 12, 1935, Serial No. 54,121

5 Claims.

This invention relates to apparatus for applying a uniform, resilient, non-woven, layer of fibrous material to backing sheets. More particularly it relates to a machine for rapidlyand efilciently applying non-Woven fibrous material to backing sheets and trimming the excess fibrous material from the marginal edges thereof in order to provide a neat, uniform finish.

The specific embodiment of the invention herein "illustrated and described relates to a machine which is primarily adapted for performing one step in the manufacture of inner trim panels for use in automotive vehicles. Trim panels of this general typeare used for the purpose of providing a finish for various sections of the interior construction of closed automobile bodies. These panels generally comprise a relatively stiff backing sheet, usually formed of cardboard or'other suitable stiif fibrous sheet, a layer of padding 72o material, and an outer finish trim of suitable woven fabric. The backing sheets, the padding, and the outer trim are secured together to provide a unitary structure which is generally secured in place by means of screws, garnish moulding, or other means conventional in the art.

While it will apparent from the following specification that the generic inventive concept herein disclosed will find great utility in many other fields where it is desirable to apply a layer of non-woven fibrous padding to a backing sheet or'other surface, the invention will find specific and important utility in applying non-woven, fibrous padding material to the backing sheets of inner-trim panels.

It is a general object of the present invention to provide a machine of this general type which will serve to rapidly, serially prepare a plurality of backing sheets and provide therein a substantially uniform layer of. non-Woven fibrous padding, adhesively bonded thereto.

Yet another object'of the present invention consists in the provision of novel and effective means for treating the edges of the sheet after the padding material has been applied thereto in order that the padding at the marginal edges of these sheets will be trimmed to provide a substantially uniform finish.

Yet another object of the present invention consists in the provision of automaticallyoperated brushes which serve automatically to treat all the marginal edges of the sheets in order that an attractive finish may be applied thereto.

Still further the present invention contemplates the provision of mechanical meansfor forcing the fibrous material at the marginal edges of the sheets into engagement with the brushes acting thereon in order that a full and complete trimming of fibrous material will be obtained.

In order to obtain a full and more complete understanding of the present invention, reference may be had to applicants prior co-pending application, Serial No. 49,140, filed November 11, 1e35, relating to this same general subject matter, wherein the general apparatus disclosed in this application is diagrammatically shown and the particular method utilized is described and claimed in detail.

Many other and further objects and advantages of the present invention will become apparent from the following specification when considered in connection with the accompanying drawings forming a part thereof.

In the drawings:

Fig. l is a perspective view'showing an innertrim panel particularly adaptable for manufacture by the apparatus of the present invention.

Fig. 2 isan enlarged, fragmentary, sectional view taken on the line 2-2 of Fig. 1 showing in detail-the construction of the inner-trimpanel.

Fig. 3 is a plan view. of a machine embodying the inventive concept of the present invention and showing the relative position of the various units thereof.

"Fig. 4 is a vertical, longitudinal sectional m'ew through the apparatus shown in Fig.3.

Fig. 5 is an enlarged fragmentary top plan view of the portion of the machine in which the fibrous material is prepared and distributed on the surface of the adhesive coated backing sheets.

a-Fig. 6 is a side elevation of the portion of the machine shown in plan of-Fig. 5 showing in detail the operation thereof.

Fig. 7 is an enlarged vertical sectional view takenon the line li of Fig. 3 showing in detail the mounting and functioning of one of the side edge brushes used forv finishing the-lateral side edges of thetrim-panel and the means for positioning the panel with respect thereto.

Fig. 8 illustrates a modified form of means for positioning the trim-panels with respect to the trimming brush.

Fig. 9 is a sectional view taken on the line 99 of Fig. 7 "illustrating in detail the manner in whiclrthe side trimming brushes operate upo the trim-panels.

Fig. 10 is a perspective view of a portion of a trim-panel havingthe fibrous padding material partially trimmed from the edges.

Fig. 11 is a sectional view of a padded trimpanel, such as is shown in Fig. 10, showing the manner in which the top and bottom marginal edges thereof are finished by the machine of the present invention.

Fig. 12 illustrates a modified form of the invention in which different means are used for urging fibrous material into the brushes and compacting the material on the backing sheets.

Fig. 13 shows a still further modified form of the apparatus shown in Fig. 12.

Fig. 14 shows a modified means of applying adhesive to the backing sheets in which a spray is substituted for the rolls shown in Figs. 3 and 4.

With more particular reference to the drawings, the specific embodiment of the invention disclosed therein comprises generally a stationary and permanently mounted work table having legs ill and a table surface ll interrupted at suitable intervals throughout its longitudinal length to facilitate the mounting of feed rollers and other conveyor mechanisms hereinafter described therein. This work table is of a length suificient to accommodate all of the apparatus hereinafter described and has mounted adjacent the rear end thereof a pair of feed rollers l2 extending substantially transversely of the table, and having their upper peripheries lying substantially in the plane of the upper surface thereof. Mounted above the feed rollers I2 is an adhesive applying roll it which, as will be seen by reference to Fig. 4, is mounted between the rollers I2 and at all times will be maintained out of contact therewith. Adhesive is applied to the adhesive applying roll 13 by means of a pair of rollers M, one of Which engages a pickup roll 15, which is rotatably driven and partly submerged in a reservoir i6 containing a suitable supply of liquid adhesive. It will be seen that liquid adhesive in the reservoir it will be picked up by the roll l5 and transmitted by means of the rolls l4 to the adhesive applying roll l3. Due to the co-action of these rolls, it will be appreciated that a substantially even and uniform layer of adhesive material will be applied to the adhesive applying roll l3.

Backing sheets 20, formed of any suitable relatively stiff sheet material and cut to a configuration substantially the same as the finished panel which they serve to provide backing for, are normally fed along the work table II and are'inserted between the feed rollers l2 and the adhesive applying roller IS. The relative vertical position of the adhesive applying roll 13, with respect to the feed rollers l2, may be adjusted in order that the desired pressure on the backing sheets may be obtained to apply the desired coating of adhesive uniformly thereover. Co-action of the feed rollers 12 and the adhesive applying roll I3 serves to feed the backing sheets forwardly and at the same time apply a substantially uniform coating of liquid adhesive material to the upper surface thereof. If desired, an atomizing spray 6 may be used for applying the liquid adhesive to the sheets in place of the rollers shown in Figs. 2 and 3. This modified form of adhesive applying means is shown in Fig. 14. The spray 6 may be of any desired form and is preferably enclosed within a housing 1 in order that the area to which the spray is applied may be accurately and definitely controlled;

In the intermediate section of the work table H, suitable feeding means are provided for conveying the sheets from the adhesive applying unit forwardly along the table. Although any suitable feeding mechanism may be used for this purpose, it has been found preferable toutilize a belt conveyor 25 comprising a feed belt 25 driven by front and rear rollers 26 and 21 respectively. This belt conveyor may be driven by means of a suitable electric motor 28 operating through a drive belt 29 to a pulley 30 on the shaft of the roller 27. The shaft of this roller 2'lmay also be provided with a sprocket Wheel 3| which serves by means of a suitable sprocket chain 32 to drive the pickup roll I5, the feed rollers I2, and the adhesive applying roll 13. It will therefore be appreciated that the feed rollers i2 and conveyor belt 25, being driven from the same source, will be run substantially synchronously and effeet a uniform movement of backing sheets longitudinally along the work table. If desired, the idle rolls 14 may also be driven by means of suitable intermeshing gears.

It will be seen that the feed rollers I2 are situated sufiiciently close to the conveyor belt 25 so that as the sheets leave the adhesive applying roll 53, they will be carried forwardly along the work table at substantially uniform speed by means of conveyor belt 25.

At the forward end of the conveyor belt 25 means are provided for accurately positioning and aligning the sheets as they leave the conveyor belt. While various means may be conveniently used for this purpose, by way of illustration Fig. 5 of the drawings shows a pair of guide bars 35. These guide bars 35 are urged toward each other by means of leaf spring elements 36 mounted on the work table. The bars, at their rearward ends, are preferably beveled off to facilitate the entrance of the backing sheets therebetween. The light inward pressure exerted by the leaf springs 36 is relatively light and merely serves to engage the side marginal edges of the backing sheets as they pass along the conveyor belt 25 and maintain the sheets in proper longitudinal alignment with respect to the Work table.

Above and substantially centrally of the conveyor belt 25 is arranged apparatus for distributhesive covered backing sheets. This apparatus is shown in detail in Figs. 3 and 4.. It comprises generally a Garnett machine 40, into which is fed fibrous material, such for example as loose non-woven jute fibers. This machine serves to shred this fibrous material, distributing the fibers at random and they are picked up by means of a toothed roller 4! journaled in the machine. A vibrating comb 42 adapted to engage toothed roller ll serves to remove the loose fibrous material therefrom and distribute it in a substantially uniform layer on a conveyor belt 43 extending outwardly from the Garnett machine. The operation of this apparatus is substantially continuous and it will be appreciated that a substantially uniform layer of loose non-woven fibrous material will be passed on to the belt 43 by means of the comb d2. From the conveyor 43, this layer of loose, non-woven fibers is fed to a pivotally mounted conveyor belt 44 which has one end mounted adjacent the outer end of the conveyor 43 and its opposite end mounted in a pair of swinging bracket members 45. A pair of rolls 46 are journaled for rotation directly above the rolls of the conveyor 44 and have running thereon a series of belts 4'! which serve to aid in maintaining the layer of fibrous material on the conveyor 44 irrespective of the angle at which this conveyor may be disposed.

ing loose non-woven fibrous material on the adare journaled in appreciated that this ratio of movement may be desired limit depending upon One end of a pivotally mounted conveyor 50 is supported in the lower end of the bracket 45 and the opposite end of this conveyor is supported in a transversely movable carriage 48 running on a pair of trackways 41, running transversely across the work table in the longitudinal central area of the conveyor belt 25. This conveyor 50 is preferably driven by means of suitable intermeshing gears 49 actuated by the outer end of the conveyor id. The carriage 5! is adapted for reciprocatory movement transversely across the work table and automatic reciprocatory movement of this carriage is accomplished by means of a reversible drive mechanism comprising a sprocket chain 55 secured to the carriage 5i and driven by means of a suitable belt 5'3. The belt 56 serves to drive a pair of pulleys 51 and is automatically shifted to drive the carriage 5 l' in either one direction or the other by an impediment operated belt shifting mechanism 58. The belt shifting mechanism 58 comprises a pair of stop members 59 disposed upon a transversely movable rock shaft, which stop-members are adapted to be operated by the carriage 5i causing a shifting of the belt 56 to drive the carriage in the opposite direction.

the carriage 5i and are driven to feed material passing from the conveyor 5%) downwardly on to the conveyor belt 25 and consequently on to the surface of the adhesive covered sheets positioned therein.

Inasmuch as the reciproc'atory movement of the carriage 5| will substantially alter the vertical position of the bracket 45, due to the constant change in inclination of the conveyor 58, means are provided for automatically varying the position of this. bracket with respect to the work table. Any suitable means may be provided for this purpose and in Fig. 6 of the drawings are shown counter-balance weights 65 connected by means of suitable cablesiifi passing over pulleys 61 and connected to the upper end of the brackets 45. It will be appreciated that these counter-balance weights 65 may be sufliciently heavy to maintain the bracket 45 in the desired vertical position irrespective of the transverse reciprocatory movement of the carriage 5|.

From the foregoing, it will be appreciated that a substantially continuous uniform layer of iibrous material will be fed from the Garnett ma chine 40 onto the'conveyor belt #3. layer of loose, non-woven fibrous material will be carried upwardly along the conveyor belt 44 and delivered on the surface of the conveyor 50 which will carry this material downwardly and feed it between the distributing rolls GZ-carried in the carriage 5|. Due to the continuousand automatic reciprocatory movement of the carriage 5i, this fibrous material will be substantially uniformly distributed over the adhesive covered surfaces of the backing sheets passing along the conveyor belt 25 underneath the carriage 56. While any relative rate of movement of the carriage 5! with respect to the conveyor belt 25 may be provided, depending upon the desired thickness of the layer of padding material which is to be applied to the backing sheets, I havefound it desirable in preparation of described herein to provide a ratio of movement between these parts; whereby the carriage 5! makes a sufiicient number of complete trips transversely across the conveyor belt while theconveyor moves a backing sheet forward substantially the vertical length of the sheet to provide an adequate layer of padding. It will be readily A pair of distributing rolls 6? anism, a substantially uniform This thin;

panels of the'type varied within any the thickness of the layer of padding which itis desired to apply and also depending upon the rate at which the fibrous material is delivered from the particular Garnett machine used.

The sheets leaving the conveyor belt25 are immediately fed between a feed roller It and a compacting rollli cooperating therewith toprovide a forward feeding movement of the sheets along the work table. The compacting roll H is preferably formed of some hard non-resilient material, such for example as hardwood, and serves to compressand compact the layer of fibrous material distributed on the adhesive covered backing sheets in order to establish a strong, permanent adhesive bond of the. fibrous material with the backing sheets.

Forwardly of the feed rollers and H and having their upper peripheries substantially lying in the surface of the work table are a pair of transverselydisposed brushes l2 and 13. These brushes are of a length slightly greater than the transverse width of the backing sheet-s and are preferably driven to rotate in opposite directions. These brushes are pref high speed by means of a suitable electric motor 58 and belt E39. Cooperating with the brushes l2 and T3 are arranged a pair of soft resilient rollers Id and 15, which serve to maintain the backing sheets in engagement with these brushes. While any suitable means may be employed, such for example as a mechanical conveyor for returning the material removed from the sheets by the brushes, the specific embodiment'of the invention herein" shown utilizes pneumatic means. The brushes l2 and 13 are housed within a suitable casing H which communicates through a conduit [8 with' a blower 19, which serves to return the fibrous material brushed from the sheets by the. brushes [2 and 13 to the Garnett machine in order that this fibrous material will be reclaimed and subsequently used on other backing sheets.

It will be appreciated that as the backing sheets are fed serially into the machine that some slight space will inherently exist between them as they move forwardly along the work, table. Due to the consistent and uniform operation of the reciprocal fibrous material distributing mechmatted layer of fibrous material will be distributed not only on the backing sheets but will also lie in the spaces between adjacentsheets as they move along the table. This material between the adjacent edges of the sheets as they move longitudinally along the table will be forced downwardly into the brushes i2 and 13 as the sheets passthereover by means of the soft, resilient, auxiliary rollers 14 and 15. Due to the fact that the brushes '52v and 13 are rotating in opposite directions, they will immediately take hold of this fibrous material between the adjacent marginal edges of the sheet and draw this material downward into the hous ing 11 from whence it will be returned to the Garnett machine in the manner described above. The rollers 14 and serve to grip the fibrous ma-' terial. at the edges of the sheets in such a man ner that the brushes serve to shear the excess therefrom and impart a neat bevelled appearance to the padding thereon.

It has been found that the use of these brushes 7 rotating in opposite directions at relatively highspeed serves effectively to trim the fibrous material top and bottom edges of the backing sheet in'a very neat and uniform manner and subjects all sheets passing thereover to substantially uniform treatment. It will be appreciated that the auxiliary rolls I4 and I5 serve as mechanical means for urging the fibrous material at the marginal edges of the sheet into engagement with the brushes I2 and 13, The suction set up by the blower 19 may tend to create an area of low pressure adjacent the brushes I2 and I3, and may to some extent serve to provide pneumatic means, in addition to the mechanical means, for urging the excess fibrous material at the top and bottom edges of the sheet into engagement with the brushes I2 and 73. After the backing sheets have passed over the brushes I2 and 73 they are fed between a pair of feed rolls 80 and 8|. The lower of these rolls 80 may be mounted for rotation transversely of the work table having its periphery lying substantially in the surface thereof. The upper roll 8| may be of hardwood substantially of the same construction as the roll H described above and serve to cooperate with the roll 80 in order to further compact and consolidate the mass of fibrous materials adhesively secured to the backing sheet.

Forwardly of the feed rolls 80 and (II, located at the lateral side of the work table and spaced apart substantially the width of the backing sheets, are a pair of brushes adapted to trim the excess fibrous material from the side edges of the backing sheets. This apparatus is shown in detail in Figures 7 and 9 of the drawings. A framework 85 is arranged above the work table and downwardly projecting arms 86 serve to support rotary brushes 8'! journaled for rotation in the arms 86 and adapted to rotate about an axis longitudinally of the work tableI I. One of these brushes 8'! is preferably located at either side of the work table and since both are of identical construction one only will be described herein in detail.

The brush 8'! is preferably driven at relatively high speed by means of an electric motor 88 mounted on the arm 86 and supplying rotary movement to the brush 8'! by means of a suitable belt 89. Also carried on the arm 85 are a pair of guiding jaws which serve to accurately position the brushes 8'! with respect to the backing sheets. These guiding jaws preferably comprise a stationarylower jaw 90 which is preferably flared to facilitate the entry of the padded backing sheet between the jaws, and a spring pressed upper jaw 9| which is urged downwardly into engagement with the sheet by means of a plurality of springs 92 exerting a slight resilient downward pressure on the upper jaw. These upper and lower jaws 90 and SI serve accurately to position the brushes 8'! with respect to the backing sheets. Resiliently mounted inclined rigid guides 9 serve to position the padded backing sheet transversely with respect to the brushes 81. From the foregoing, it will be appreciated that as the padded backing sheets are fed along the work table, the guides 94 will serve to position the brushes accurately transversely of the work table with respect to the edges of the sheets in order that the brushes 81' will brush the excess fibrous material away from the edges and trim these edges neatly. It has been found desirable to mount the brushes 8'! on an axis of rotation slightly above the plane of the work table in order that the trimming action of these brushes will impart a slight bevel to fibrous material at the edges of the backing sheets as they pass thereby. The brushes 8'! are each preferably housed in a suitable conduit 95 which communicates with the conduit 78 constituting the intake of the blower I9 in order that the fibrous material trimmed from the side lateral edges of the sheets will likewise be returned to the Garnett machine. A pair of feed rollers 98 and 99 are located forwardly of the side trimming brushes and serve to conduit the backing sheets therefrom, and it will be appreciated that as the backing sheets leave the feed rollers 98 and 99, they will not only have a uniform layer of padding adhesively bonded and compacted on the surface thereof, but that the marginal edges of this padding will be accurately and uniformly trimmed to remove the excess fibrous material therefrom.

As is conventional in the art, the backing sheets may be subsequently provided with a suitable reveal covering of fabric. In Figures 1 and 2 is shown a completely finished trim panel. In the sectional View shown in Figure 2 it will be clear that a backing sheet I01 has a layer of padding I02 firmly bonded thereto by means of a thin uniform layer of adhesive I03. A suitable section of fabric trim material I05 serves to cover the layer of padding I62 and this material may be stitched in any suitable manner along vertical lines I04 directly to the backing sheet IIJI. The side marginal edges of this fabric material IE5 may be carried around and adhesively secured to the reverse side of the backing sheet I III In Figures 10 and 11 are shown enlarged detail views of the structure of the padded trim panel partially completed. It will here be seen that the cardboard backing sheet IGI has a substantially uniformly distributed layer of fibrous material I02 secured thereto by means of a layer of adhesive IE3. The rear portion of this trim panel which has not been operated upon by the trimming brushes shows the fibrous material extending substantially out over the side marginal edge of the backing sheets. The forward portion of this backing sheet clearly illustrates the manner in which the side trimming brushes serve to remove this excess fibrous material and create a backing sheet which is sufficiently completely finished in order that the fabric reveal trim may be applied thereto without necessitating subsequent operations. The sectional view shown in Figure 11 illustrates the manner in which the transversely disposed brushes l2 and 13 serve to trim the top and bottom marginal edges of the trim panel. Due to forcing the fibrous material at the edges of these panels into engagement with the rotary brushes, it has been found that the pulling of the fibers from the marginal edge of the sheet serves to bevel the top and bottom marginal edges of the padding substantially in the manner illustrated at I06 in Figure .11.

In Figure 8 is illustrated a modified form of the invention in which a resilient idle roll I63 is used in place of the upper jaw 9i. This idle roll I08 is preferably formed of soft resilient material such for example as sponge rubber and serves to cooperate with the lower jaw 90 in order to hold the fibrous material on the backing sheets during the brushing operations.

In Figures 12 and 13 are shown modified means for holding the padding material in position. In the form of the invention shown in Figure 12, rollers I08 and I89 are arranged to cooperate with the feed rollers III and 8!] respectively. A small roller H0 is journaled above the brush I2 and an endless'belt is carried on the rollers I08 and II I) serving not only to compact the fibrous padding but to urge the excess at the marginal edges into engagement with the brush 12. A roller H2 and belt II3, similar to the roller II 0 and belt III, are arranged to cooperate with the brush '13 for the same purpose.

If desired the rollers '14 and 15 may be dispensed with and the apparatus shownin Figure 13 sub-- stituted therefor. 'This apparatus comprises a stationary transverse bar -I I5 which has permanently secured thereto a plurality of resilient fingers Ilfi which exert a slight downward pres sure on the fibrous material, urging it into engagement with the brush with which it is associated.

padded backing sheets therealong, 'movably mounted brushes at the sides of the conveyor for removing the excess'padding from. the side marginal edges of said sheets, and rotary brushes extending transversely of the conveyor for removing the excess paddingfrom the top and botto edges of said sheets. 1 a r 2. In a conveyor system means for moving a series of padded backing sheets therealong, a rotary brush movably mounted adjacent the edge, of said conveyor system, means for moving ,said brush to trim the excess fibrous material from the side edges of said sheets as they pass there-- along, a housing for said brush and means carried by said housing for engaging said sheets and positioning said brush with respect thereto.

3. Apparatus for trimming padded backing sheets comprising a. pair of aligned conveyors spaced from each other and serving to feed a series of padded backing sheets through said ap paratus, a pair of rotary brushes disposed in the space between the adjacent ends of said conveyors and having theperipheral surfaces thereof extending above theplane of'said'conveyors, and

conveyor beltsarranged above said brushes servr ing to feed articles from one conveyor to the other over said brushes and serving to urge said articles into engagement with said brushes as the 7.

same are fed from one conveyor to the other.

4. Apparatus for trimming padded backing sheets comprising a pair of aligned conveyors spaced from. each other and servingto feed a series of padded backing sheets through said apparatus, a pair of rotary brushes disposed in the space between the adjacent ends of said conveyors and having an arc of the peripheral surfaces thereof extending above the plane of said conveyors, conveyor belts, arranged above said brushes serving to feedarticlesfrom one conveyor to the other over said brushes and serving to urge said articles into engagement withsaid brushes as the same are fed from one conveyor to the other,

and means for drivingsaid rotary brushes to rotate the same in opposite directions' 5. Apparatus of the 'classdescribed comprising a conveyor for fe'edinga series of padded backing sheets through said apparatus, pivotally mounted support members disposed at each of the lateral sides of said conveyor, rotary brushes carried by said support members whereby said rotary brushes may be moved inwardly or outwardly with respect to the lateral sides of said conveyor and means carried by said support mem- CLARENCE w AVERY. 

